A re-sealable package for loose smokable material

ABSTRACT

A re-sealable cuboid-like package for loose smokable material formed from a one-piece multilayer blank. The package includes a receptacle portion ( 6 ) for containing loose smokable material ( 4 ) with an access opening ( 28 ) and a flap ( 8 ) moveable between a folded position, in which the flap is folded at least partly around the receptacle and overlies the opening, and an extended position, in which the flap extends outwardly from the receptacle portion. A re-sealable cover layer ( 30 ) is attached to an inner surface of the flap ( 8 ) to enable movement of the layer between a closed position in which it covers the access opening and an open position in which the access opening is substantially uncovered, the cover layer being sealed in place by a repositionable adhesive.

The present invention relates to a re-sealable package for loose smokable material.

Fine cut tobacco for the manufacture of roll your own (RYO) and make your own (MYO) cigarettes is conventionally sold in re-closable, flexible, plastic pouches. Such pouches are often provided with an elongate flexible flap that is folded around the pouch in order to close it.

Box-like rigid tobacco containers have also been introduced for storing loose tobacco material, such as that described in WO 2007/007197. The package is generally formed from a one-piece blank to provide a receptacle portion for containing the loose material, the receptacle having a front wall, rear wall and opposing side walls and having an access opening. A closure flap extends from the rear wall and is moveable between a folded position, in which the flap is folded around the receptacle portion to at least partially cover the front wall and overlie the access opening, and an extended position, in which the flap extends outwardly from the receptacle portion to allow access to the contents of the package. The flap and front panel are provided with co-operating means, such as a tab and slot, a hook and loop arrangement or a re-sealable adhesive, to allow the flap to be secured to the receptacle when access is not required.

Loose tobacco for RYO and MYO cigarettes has a greater moisture content than the type of tobacco used in conventional cigarettes. RYO and MYO tobacco has a moisture content of typically above 14 weight percent. In comparison, pre-manufactured cigarettes typically have moisture content below about 14 weight percent. The high moisture content enables the tobacco to be more easily handled by the user for insertion into a tube or for formation into a roll. It is important that the tobacco is sealed within the container prior to use to prevent the package contents from drying out. This may be achieved, for example, by shrink wrapping the product with a transparent polymeric film. WO 2007/007197 provides a closure tongue detachably connected to the receptacle portion. Prior to first use, the tongue extends over the access opening but can be detached to allow access to the contents of the receptacle. Following first use, the receptacle is then closed by means of the closure flap.

WO 98/54060 describes a flexible pouch of plastics material for storing loose tobacco, the pouch comprising a pocket for containing the tobacco, the pocket having a mouth for access to the interior of the pocket and a flap capable of folding over the pocket at or near the mouth. The pouches are filled with material, sealed and wrapped for sale to the consumer. This seal is broken upon opening of the pouch by the consumer but the package is provided with a re-closable fastener like a zip lock at the mouth of the pocket to re-seal the pouch. The plastics material of the pouch also aids moisture retention within the package. However, the handling of such a three dimensional object like a zip lock is relatively challenging on fast moving packaging apparatus.

One object of the present invention is to provide an improved re-closing mechanism for a tobacco container or pouch for storing loose tobacco wherein the receptacle is re-sealable after first use, thereby maintaining the moisture content and freshness of the tobacco and preventing loose material from falling out of the pouch.

In a first aspect of the invention, a re-sealable substantially cuboid package for storing loose smokable material is described. The package is formed from a one-piece multilayer laminar blank, and includes a receptacle portion for containing loose smokable material and having an access opening; a flap integral with the receptacle portion and moveable between a folded position, in which the flap is folded at least partly around the receptacle portion and overlies the opening, and an extended position, in which the flap extends outwardly from the receptacle portion; and a re-sealable cover layer moveable between a closed position, in which the cover layer at least partially covers the access opening and an open position, in which the access opening is substantially uncovered, the cover layer being moveable between the closed and open positions by attachment to an inner surface of the flap.

The present invention provides a simple mechanism for re-sealing a one-piece package after first opening thereby retaining the moisture content of the loose tobacco that remains in the package. The freshness of the contents is also maintained and the re-sealable cover layer serves to prevent loose tobacco falling out of the package between uses.

The term ‘loose smokable material’ is used to describe smokable material that has not been manufactured into a smoking article such as a cigarette, cigar or cigarillo or part thereof and includes, but is not limited to, rolling tobacco, pipe tobacco, chewing tobacco and snuff. Preferably, the loose smokable material is loose tobacco, more preferably rolling tobacco. Preferably, the tobacco is fine-cut, having a cut width of 0.3-0.9 mm. When the loose smokable material is rolling tobacco, the receptacle portion of the package preferably contains between about 40 ml and 250 ml tobacco. Preferably, the loose tobacco is not wrapped inside the package; it is in direct contact with the receptacle portion of the container. The loose material may, however, be contained in an inner pouch, bag or other wrapper which is contained within the receptacle portion of the package.

The package according to the invention is substantially cuboid forming a cup-shaped receptacle portion having a mouth for accessing the contents of the receptacle and a flap for folding over the receptacle portion. More preferably, the package is rectangular in cross-section and is in the form of a carton. It will be appreciated that through appropriate choices of the dimensions of receptacle and flap, containers according to the invention may be designed for containing different volumes of loose smokable material.

The receptacle portion may include a base or bottom wall, a front wall, a left side wall, a right side wall and a rear or back wall. The flap extends from the rear wall and is foldable to at least partially overlie the front wall in the folded position. The front wall and back wall have a larger surface area than the side and bottom walls. More preferably, the width of the front and rear walls between the side walls is substantially greater than the height of the front and rear walls.

The package is formed from a one-piece or single multilayer blank made from any suitable material that enables the package to have a degree of flexibility and possess moisture-barrier properties. Preferably, the package is formed from a one-piece multilayer blank, more preferably from a one-piece multilayer film laminated blank or a one-piece aluminium foil laminated blank which provides a moisture barrier. More preferably still, the package is formed from a laminated paper coated with polyethylene on the intended inside of the package or a sandwiched layer of thin aluminium foil between an outer kraft paper or board and an inner polyethylene coating.

Use of a plastics laminated multilayer blank to form the package provides a container that is not damaged by the moisture content of the loose tobacco and aids retention of moisture within the tobacco product. This advantageously helps to prevent the package from spotting due to, for example, moisture present in the loose smokable material contained in the receptacle portion of the package. In addition, use of a laminated blank can be used to enhance the appearance of the package. For example, the film can be metallised or printed with an overall ink before lamination to, for example, create a metallic or coloured appearance when the flap is in the extended position.

Optionally, the flap of the package may comprise two or more hingedly connected panels, a first hinge line extending between the rear wall of the receptacle and a first panel of the flap, and a second hinge line extending between the first panel and the second panel of the flap, whereby in the folded position, the second hinge line overlies a top edge of the front wall of the receptacle to provide a closed, cuboid-like package. The term “hinge line” refers to a line about which the flap, or panels of the flap, may be pivoted to open the container. A hinge line may be, for example, a fold line or a score line in the panel forming the back wall of the housing.

In the extended position, the flap advantageously provides a surface on which a consumer can handle loose smokable material removed from the receptacle portion of the package. For example, a consumer may use the surface provided by the flap to roll a charge of loose smokable material removed from the receptacle portion in a wrapper to form a hand rolled cigarette. Alternatively, the consumer may use the surface provided by the flap to stuff a charge of loose material removed from the receptacle portion in a pre-fabricated tube to form a smoking article. The surface provided by the flap in the extended position may advantageously be provided with, for example, graphics, text, logos or other consumer information.

The cover layer is preferably dimensioned to overlie the access opening. Preferably, the cover layer is formed integrally with the walls of the package and is at least partially detachable therefrom upon first opening of the package to expose the access opening. The cover layer or perimeter of the access opening may be provided with a repositionable adhesive for re-securement of the cover layer to the receptacle portion to re-seal the access opening after first use.

In one embodiment, the cover layer is attached to an adhesive label that is attached to the inner surface of the flap, the adhesive label re-attaching the cover layer to the receptacle portion. The adhesive label may form the entirety of the cover layer.

The re-sealable package according to the invention may further comprise a top panel extending at least partially across the opening of the receptacle portion, wherein the package comprises a front wall, back wall, opposing side walls and a bottom wall with a top panel provided between the intended top edges of the side, front and back walls. The front panel is provided with an aperture for forming the access opening that is covered by the cover layer in its closed position. The aperture may extend at least partially into the front wall of the receptacle portion.

Preferably, prior to first use, the cover layer forms part of the top panel and is provided with at least one line of weakness whereby during first opening of the package, the aperture is formed by at least partially separating the cover layer from the top panel along the at least one line of weakness. Preferably, two substantially parallel lines of weakness are provided in the top panel for forming the cover layer between these lines. However, it is to be appreciated that the line of weakness can take any suitable shape or combination of shapes. Preferably, the line of weakness defines a cover layer that has three sides that separate the cover layer from the receptacle portion, and a fourth side that remains attached to the receptacle portion. A hinge line may be provided between the fourth side and the receptacle portion. The cover layer is attached to an inner surface of the flap of the package such that upon opening the flap the cover layer is separated from the front or top panels of the receptacle portion along the lines of weakness.

The line of weakness can be continuous or discontinuous (for example, perforated). Further, the line of weakness can be formed using any suitable technique or combination of techniques, for example, laser cutting or mechanical cutting (for example, die cutting or kiss cutting). The line of weakness can include any suitable depth in a direction transverse to the front and top panels.

Preferably, at least the top panel but more preferably, all of the package is formed from multiple layers and the cover layer is formed from one of these layers. For example, the top panel may comprise an outer layer and an inner layer and the line of weakness has a depth that is at least about 90 percent of a total thickness of the outer layer. More preferably, the line of weakness has a depth that is about 100 percent of the total thickness of the outer layer. Any suitable percentage of material can remain along the line of weakness after the line has been formed. Preferably, between about 5 percent and about 25 percent of the material of the outer layer remains along the line of weakness after the line has been formed.

The walls and top panel of the package preferably comprise at least the inner and outer layers, with the cover layer comprising part of the outer layer. The inner layer can also include the access opening through which the smokable material can be removed. The access opening is covered by the cover layer formed in the outer layer when the cover layer is in the closed position. Further, the access opening is at least partially uncovered when the cover layer of the outer layer is in the open position. In one or more embodiments, the access opening is completely uncovered when the cover layer is in the open position.

The access opening can be disposed in any suitable location on the receptacle portion. In one or more embodiments, the access opening can be disposed such that it is located on the front wall of the package. In one or more embodiments, the access opening can be disposed such that it is located on the top panel of the package. In one or more embodiments, the access opening can be disposed such that it is located across a portion of the front wall and the top panel of the package.

The access opening can take any suitable shape or combination of shapes. Further the access opening can be formed using any suitable technique or combination of techniques, for example, laser cutting or mechanical cutting (for example, die cutting).

The inner layer may be attached to the outer layer using any suitable technique or combination of techniques. Preferably, the inner layer is attached to the outer layer using a permanent adhesive. Any suitable adhesive or combination of adhesives may be utilized. In contrast, the cover layer is re-attached to the front wall and top panel by a repositionable adhesive. Any suitable repositionable adhesive can be utilized, for example, a pressure sensitive adhesive.

The outer layer can have any suitable dimensions relative to the inner layer. In one or more embodiments, the outer layer is coextensive with the inner layer. In other words, the outer layer extends to an outer perimeter of the inner layer. In this embodiment the outer layer may be provided with two substantially parallel first lines of weakness at a first distance apart and the inner layer provided with two substantially parallel second lines of weakness at a second distance apart, the first distance being greater than the second distance. Re-sealable adhesive is applied between corresponding first and second lines of weakness provided on the cover layer and inner layer respectively to provide two substantially parallel lines of re-sealable adhesive along at least a partial length of the cover layer.

At least a portion of the outer layer comprising the cover layer can be permanently affixed to a corresponding portion of an inner surface of the flap of the package. Any suitable technique or combination of techniques can be utilized to affix this portion of the cover layer to the inner surface of the flap of the box. Preferably, a permanent adhesive is used to attach the portion of the outer surface of the cover layer to the flap.

The cover layer is adapted to reattach to the inner layer of the top panel and front wall when the flap is in the closed position. In one or more embodiments, an alternative or additional adhesive or adhesives can be disposed along at least a portion of the inner layer along a perimeter of the access opening disposed in the inner layer such that the closure layer can be attached to the inner layer when in the closed position. This portion of the inner layer along the perimeter of the access opening defines a seal region of the inner layer. The cover layer is adapted to overlap the access opening into the seal region such that the cover layer attaches to the inner layer within the seal region when the flap is folded and the cover layer is in the closed position. The adhesive disposed between the cover layer and the seal region allows for repeated opening and closing of the cover layer so that the consumer goods disposed within the receptacle portion of the package can be accessed when the flap and cover layer are in the open position, and so that the consumer goods remain sealed within the package when the flap and cover layer are in the closed condition.

The alternative or additional adhesive can be disposed in any suitable location between the cover layer and the seal region. In one or more embodiments, this adhesive can be disposed on the cover layer. In such embodiments, the adhesive can be disposed on the inner surface of the cover layer such that it covers the entire cover layer. In one or more embodiments, this adhesive can be disposed along at least a portion of a perimeter of the cover layer corresponding to the seal region when the cover layer is in the closed position. Further, in one or more embodiments, the alternative or additional adhesive can be disposed on the cover layer and the inner layer.

The package may further comprise retention means for holding the flap in the folded position. The retention means may comprise a tab provided on one of the receptacle portion or the flap and a cooperating slot provided in the other of the receptacle portion or the flap, the slot being positioned to accept the tab when the flap is in the folded position. Alternatively, the retention means corresponding magnetic regions provided on the flap and the receptacle portion or a re-sealable adhesive applied to at least part of the flap or receptacle portion.

It is to be appreciated that a variety of other known retention means could be employed to hold the flap in the folded position in addition to those specific examples given above.

The packages according to the invention may further comprise one or more pockets in or on the receptacle portion or flap for storing cigarette papers, cigarette lighters, rolling machines or other such items. In addition, packs of cigarette papers for making roll your own cigarettes may also be attached directly to the receptacle portion or flap of the package according to the invention by means of, for example, adhesive.

Due to the relatively high moisture content of the RYO or MYO tobacco contained within the package, it is preferable to heat the packaged tobacco such that the tobacco is pasteurized. For example, the loose tobacco may be arranged in a closed package according to the invention and then heated between about 55 to 120 degrees Celsius, preferably between about 60 to about 85 degrees Celsius. The pasteurization treatment reduces the number of viable microorganisms in the package and prolongs shelf life. Any appropriate heating method may be used, such as by use of heating medium or microwave radiation.

If desired, the packages according to the invention may be shrink wrapped or otherwise over wrapped with a transparent polymeric film of, for example, polyethylene or polypropylene in a conventional manner.

According to another aspect of the invention, there is provided a multilayer blank for forming a package according to the first aspect of the present invention. To this end, there is an unfolded multilayer blank comprising rolls of sealable packaging material cut into predetermined shapes and having mechanical crease lines therein to allow folding of the blank to form the package. Appropriate sealing of parts of the blank is carried out to create the finished package using any conventional sealing techniques, for example using heat sealing, cold sealing or ultrasonic sealing methods.

Referring now to the drawings, in which some aspects of the present invention are illustrated:

FIG. 1 is a schematic perspective view of a package containing loose smokable material according to an embodiment of the present invention, shown in a closed position; and

FIG. 2 is a schematic perspective view of the package shown in FIG. 1, shown in an open position;

Referring to FIGS. 1 and 2, a schematic perspective view of an embodiment of a re-sealable package or pouch for storing loose smokable material, such as roll-you-own tobacco, pipe tobacco or chewing tobacco, is depicted. A cuboid one-piece package 2 formed from formed from a single multilayer laminar blank comprises a receptacle portion 6 and an elongate closure flap 8 is connected to the receptacle portion by hinge-line 10. Loose tobacco 4 is stored within the receptacle portion. The receptacle portion comprises a front wall 12 and an opposed parallel rear wall (not shown), a bottom wall (not shown), which connects the front wall 12 and the rear wall along their lower edges, a left side wall (not shown) and a right side wall 22, which connects the front wall and the rear wall and bottom wall along their left and right hand edges respectively. The walls define a receptacle portion 6 that is of a greater width than height. Additionally, a top panel 24 having an access opening 28 (see FIG. 2) extends across the top of the receptacle portion between the upper edges of the side walls, rear wall and front wall.

The elongate closure flap 8 is formed from two hingedly connected panels 8 a and 8 b, the first hinge line 10 extending between the rear wall of the receptacle and a first panel 8 b of the flap, and a second hinge line 26 extending between the first panel 8 b and the second panel 8 a of the flap, whereby in the folded position, the second hinge line overlies a top edge of the front wall 12 of the receptacle to provide a closed, cuboid-like package, as shown in FIG. 1. The free edge of the second panel 8 a is provided with a tab 40 which may be received within a slot (not shown) provided on the front wall.

The closed package as depicted in FIG. 1 is opened by releasing the tab 40 from its slot and pulling the flap 8 upwardly towards the rear of the box (see FIG. 2). Additionally, the package is provided with a re-sealable cover layer 30. Prior to first use, the cover layer 30 is provided over the access opening 28 and forms part of the top panel 24 and front wall 12 to provide a sealed receptacle portion.

The cover layer is permanently attached to an inner portion of the closure flap 8 and lines of weakness (not shown) are provided between the cover layer and the top panel and front wall. This enables the cover layer to be pulled away and separated from the top panel and front wall upon opening of the flap 8. The lines of weakness define a cover layer that has three sides that separate the cover layer from the receptacle portion, and a fourth side that forms a hinge line between the cover layer and the receptacle portion. Thus, extension of the flap detaches three sides of the cover layer from the receptacle portion while the fourth side remains attached to the receptacle portion enabling a user to then access the contents of the package through the access opening. Following use, the flap 8 is folded back over the front wall which re-positions the cover layer back over the access opening 28 to close the opening. Re-sealable adhesive is provided in a sealing region 32 to re-seal the closure layer to the top panel and front wall. This sealing region 32 may be provided around the edges of the opening 28 or along the three perimeters of the cover layer 30 that separate it from the receptacle portion. Alternatively or additionally, a repositionable adhesive label may be attached to the cover layer and the flap to re-seal the cover layer to the receptacle portion.

It is to be appreciated that each box-like package would be formed by folding and sealing an appropriate blank. In this respect, an unfolded blank comprises rolls of sealable packaging material cut into predetermined shapes and having mechanical crease lines therein to allow folding of the blank to form the package. Appropriate sealing of parts of the blank is carried out to create the finished product. The blank for forming the package is a laminated sheet made from any suitable material that enables the package to have a degree of flexibility and possess moisture-barrier properties, such as a laminated paper coated with polyethylene or a sandwiched layer of thin aluminium foil between an outer kraft paper or board and an inner polyethylene coating. The loose tobacco is packed into a package formed from the blank, sealed within the package and optionally, subjected to a heating process to pasteurize the tobacco content.

The re-sealable package of the invention enables a package to be re-sealed after first use thereby maintaining the moisture content and freshness of the tobacco material within the package and preventing material falling out of the package between uses. The re-sealing mechanism can be incorporated into a flexible pouch formed from a one-piece blank and is made from a material that does not absorb moisture from the product. The attachment of the cover layer to the flap enables easy re-sealing of the package by the user by simply folding the flap back around the front wall in the conventional manner. The package is made from lightweight materials in a compact shape and may be made from renewable raw materials (wood fibres). The packages are also single use, being recyclable, thereby avoiding the need to clean the containers before or after the filing operation. 

1. A re-sealable substantially cuboid package for loose smokable material, the package being formed from a one-piece multilayer blank, and comprising: a receptacle portion for containing loose smokable material and having an access opening; a flap integral with the receptacle portion and moveable between a folded position, in which the flap is folded at least partly around the receptacle and overlies the opening, and an extended position, in which the flap extends outwardly from the receptacle position; and a re-closeable cover layer formed integrally with the walls of the package and moveable between a closed position in which the cover layer at least partially covers the access opening and an open position in which the access opening is substantially uncovered, the cover layer being moveable between the closed and open positions by attachment to an inner surface of the flap.
 2. The re-sealable package of claim 1 wherein the receptacle portion comprises a base wall, a front wall, a rear wall and opposing side walls, the flap extending from the rear wall and being foldable to at least partially overlie the front wall in the folded position.
 3. The re-sealable package of claim 2, wherein the flap comprises two or more hingedly connected panels, a first hinge extending between the rear wall of the receptacle and a first panel of the flap and a second hinge extending between the first panel and a second panel of the flap, whereby in the folded position, the second hinge overlies a top edge of the front wall of the receptacle.
 4. The re-sealable package of claim 1, wherein the cover layer or a perimeter of the access opening is provided with a repositionable adhesive for re-sealing of the cover layer to the receptacle portion.
 5. The re-sealable package of claim 1 wherein the cover layer is attached to an adhesive label attached to an inner surface of the flap whereby the adhesive label re-attaches the cover layer to the receptacle portion.
 6. The re-sealable package of claim 1 further comprising a top panel extending at least partially across the opening of the receptacle, the top panel having an aperture that is covered by the cover layer in its closed position.
 7. The re-sealable package of claim 6 wherein the aperture extends at least partially into the front wall of the receptacle portion.
 8. The re-sealable package of claim 6 wherein the cover layer forms part of the top panel and is provided with at least one line of weakness, whereby during first opening of the package, the aperture is formed by at least partially separating the cover layer from the top panel along the at least one line of weakness.
 9. The re-sealable package of claim 8 wherein at least the top panel of the package is formed from multiple layers and the cover layer is formed from one of these layers.
 10. The re-sealable package of claim 1 wherein the cover layer is dimensioned to overlie the access opening and is provided with re-sealable adhesive around peripheral edges of the layer for securement to the receptacle portion.
 11. The re-sealable package of claim 1, wherein the receptacle portion and the flap are configured to cooperate to hold the flap in the folded position.
 12. The re-sealable package of claim 1 wherein the receptacle portion comprises a base or bottom wall, a left side wall, a right side wall and a rear or back wall, the front wall and back wall having a larger surface area than the side and bottom walls and wherein the width of the front and rear walls between the side walls is substantially greater than the height of the front and rear walls.
 13. The re-sealable package of claim 1 comprising loose smokable material within the receptacle portion, the loose smokable material being in direct contact with the receptacle portion.
 14. The re-sealable package of claim 13 wherein the loose smokable material is rolling tobacco, pipe tobacco, chewing tobacco or snuff.
 15. (canceled) 